Decorative siding panel and method of manufacture

ABSTRACT

A decorative siding panel is disclosed. The panel preferably comprises a thermoformed unit which includes upper and lower attachment flanges bordering a central area which is formed with a raised profile to simulate natural stone. The panel preferably includes means for attachment to adjacent panels forming a given horizontal course. The panels are preferably thermoformed to a desired shape, a textured coating in a series of coating stages, a color is applied to the texture and the coatings fixed to the unit.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention generally relates to decorative wall panelsand methods for their manufacture. More specifically, the presentinvention relates to a simulated stone wall covering which is comprisedof overlapping panels, and methods of fabrication.

[0003] 2. Description of the Prior Art

[0004] In the construction and finishing trades there have been manyprior attempts to simulate a brick, stone or tile surface usingmaterials less expensive than the genuine material. Some of theseattempts involved cutting the genuine brick, stone, etc. into thin slabswhich are then adhered to a conventional concrete wall, etc. forsupport. See, for example, U.S. Pat. Nos. 3,131,514; 1,669,351;3,660,214; 3,740,910; 3,521,418; 3,775,916; 3,646,715; 2,122,696;2,149,784; 2,339,489; 3,426,490; and 1,902,271. The expense, time, andcare involved in cutting the brick or stone, etc. into desired thinslabs and then adhering them to the desired surface or substrate detractfrom the advantages of such techniques.

[0005] Another attempt to simulate a brick, stone, tile, etc. exteriorinvolves pouring a mortar or concrete mix into a mold or form whichincludes the desired relief, e.g., brick, stone, etc. This technique isdescribed, for example, in U.S. Pat. Nos. 3,002,322 and 3,874,140.Various limitations are inherent in this technique. For example, inorder for the concrete or mortar mix to properly and completely fill themolds without leaving air pockets the mix must contain a considerableamount of water. This detracts from the strength of the cured mixtureand increases the curing time. The finished product unfortunately stillhas the appearance of concrete and is all the same color, i.e., it doesnot have one color for the bricks or stone relief and a different colorfor the spacing between the brick or stone shapes. Moreover, it isdifficult if not impossible to obtain sharp edges on the brick or stoneshapes in these molds. As a result, the shapes are not as realistic asdesired.

[0006] Another technique simply involves making panels or sections fromplastic which has been molded to the desired relief. The panels orsections are then used as the outer decorative facing for the structureto be covered. See, for example, U.S. Pat. Nos. 3,882,218; 3,177,279;and 3,232,017. Of course, these products do not provide a totallyrealistic appearance and would not be adequate as a substitute for realbrick, stone, tile, etc. in all situations.

[0007] Still other techniques involve making simulated brick or tileelements out of plastic and then bonding them to a supporting panel orsheet with adhesive. See U.S. Pat. Nos. 3,991,529 and 4,079,554. Again,such a technique includes serious limitations.

[0008] Yet another technique involved forming two layers of magnesiteapplied to a metal lathe. The second layer is of a different color thanthe first layer. Before the second layer hardens, grooves are cuttherethrough to form the shape of bricks, for example, and to reveal theunderlying layer of magnesite. See U.S. Pat. No. 1,583,748.Disadvantages with this technique include the lack of stone relief.Further, this process does not provide for graduation of color. Finally,the product resultant from this process requires a skilled installerusing skim coat and mortar.

[0009] Another technique described in U.S. Pat. No. 3,426,490 involvesforming individual brick veneer blocks made of concrete or fired claywhich are adhered to a wire mesh in panel form. The panels are thensecured to a wall with nails or staples. Mortar is then applied betweenthe veneer blocks and forced into the wire mesh. This technique alsosuffers as a result of its cumbersome method of application which doesnot lend itself to quick application.

[0010] U.S. Pat. No. 3,496,694 describes yet another method in whichmolded formations made from cementitious plaster, plastic, or othersuitable decorative material are adhered to a flexible base material.The prefabricated material may then be rolled up and transported to thejob site where it is attached to the frame of a building. Thedisadvantage of this method is that it requires an even flat surface formounting. This product resultant from the method requires aninstallation process which is material-intensive.

[0011] U.S. Pat. No. 3,868,801 describes a building panel for aprefabricated house. The panel includes masonry elements (such asbricks), polyester mortar, wire mesh, polymer foam, and inner facinglayers are held together by the mortar and foam.

[0012] U.S. Pat. No. 3,344,570 describes a reinforced flooring tileincluding a body of concrete with reinforcing framework embeddedtherein. The network is thermoplastic synthetic resin or metallicreinforcing.

[0013] U.S. Pat. No. 3,067,545 describes an artificial siding for framebuildings. A brick-like block is made of standard concrete block mixturewhich may include coloring pigments and water-proofing agents. The blockis molded on metal mesh in such a manner that it extends through themesh. The exterior surface of the walls of the building are covered withwooden-sheathing and then felt paper. The brick/mesh pieces are thennailed to the wall individually as siding in such a manner that the meshoverlaps the mesh of the piece in the row below it. Presumably thespaces between adjacent bricks would have to be sealed in some manner.

[0014] U.S. Pat. No. 2,819,495 describes a method for making buildingblocks having a molded mortar surfacing simulating a plurality of bricksor stones. The mortar is first placed into a mold and must be tampedinto compartments; then additional intermediate layers are added, afterwhich concrete mix is added to form the main portion of the block. Adisadvantage of this technique is that the facing is applied to theconcrete block prior to the required conventional steam or oven curingof the block. Accordingly, additional care is required to handle suchblocks prior to curing.

[0015] U.S. Pat. No. 2,748,443 describes a particular technique(involving a specially designed stencil) for applying a plastic mix,like mortar, to the face of a building in a predetermined pattern tosimulate stone blocks. However, the wall to be faced is first coveredwith lathing over which is provided a continuous coating of plastic mixand then a brown coat. Then the mortar mix is applied with the aid ofthe stencil. This technique, of course, would not be practical for usewith individual building blocks, nor is it a convenient technique evenfor large building faces.

[0016] U.S. Pat. No. 1,571,849 describes a multi-step method for makingbuilding blocks which is similar to that described in U.S. Pat. No.2,819,495. A grate is placed on a flat plate and a concrete mix is thenplaced into the openings in the grate and must be tamped down until itis even with the top of the grate. The grate is then removed and thespaces between the shapes formed by the grate are filled withcementitious compost colored differently than the shapes left by thegrate. Then another concrete mixture is added to form another layer. Theresulting structure is then removed from the mold on the flat plate andplaced in the bottom of a mold of a cement block forming machine wherethe main portion of a cement block is formed on top.

[0017] U.S. Pat. No. 2,618,815 describes a method for applying a coatingof plaster or cement to a wall to simulate the appearance of stone,cement blocks, or similar construction units. A plastic mold is filledwith a concrete and mortar mix. The mold is then placed against a walluntil the mortar mix adheres and sets. Alternatively, the mold may becoated with an adhesive coating such as a mixture of paraffin andkerosene. Marble dust, quartz particles or the like are then spread ontothe coating, followed by ground stone particles. The mold is then filledwith the mortar mix. Then the mortar mix may be pressed against the walland the mold removed immediately, leaving the marble dust andparaffin-kerosene coating covering the mortar.

[0018] U.S. Pat. No. 2,130,911 describes a prefabricated building unitin which a first layer is applied directly onto a Celotex, fiber board,etc. The first layer may be plaster or cement (0.25 to 2 inches thick).Then facing elements made from natural stone, cement, wood, metal,linoleum or the like are pressed onto the surface of the first layerwhile either or both are in a plastic or semi-cured condition.Alternatively, the facing elements may be secured to the first layer bycement or adhesive. The facing elements may be pre-formed or may beformed from a plastic material on the base member in a continuousoperation.

[0019] U.S. Pat. No. 3,304,673 describes a pre-cast panel which isadapted to be keyed to adjacent panels with specially formed inserts.The panel includes a base layer of cement and an embossed outer layerwhich simulates brick. Before the base layer is set the outer layer isadded and then a mold is impressed against the surface of the outerlayer to emboss it and provide a simulated brick facing. The outer layermay include pigments for coloring. Alternatively, the outer layer may becast in a separate mold, hardened, and then laid in place over the firstlayer.

[0020] U.S. Pat. No. 3,503,165 describes a structural panel made ofconcrete. A simulated brick appearance may be achieved by putting a thinlayer of wet concrete over the face of the panel and then pressing amold downwardly into the wet concrete to imprint a brick appearance.

[0021] Each of the methods disclosed in these prior references displaythe disadvantage of a tedious and rather involved fabrication processand/or a labor and material intensive installation process. In thisconnection, fabrication techniques which emphasize extensive use ofconcrete or stone layering may be as expensive as the materials whichthey were developed to replace. Further, many of the end results ofthese prior processes require an involved installation process. Finally,none of these prior processes achieve the goal of a low cost, lowweight, easily assembleable system, where the end result closelyreplicates stone or masonry.

SUMMARY OF THE INVENTION

[0022] The present invention addresses the above and other disadvantagesof prior decorative wall panels and methods for their fabrication.

[0023] In a general embodiment, the system of the invention includes aseries of connectable panels, where each panel comprises a one-piecesubstrate or base layer and a decorative layer bonded to the frontalsurface of the substrate. The base layer may be formed from a variety ofmaterials and may be molded into a variety of forms and shapes.Structurally, the panel includes features which allow for itsready-installation on a wall or other surface via an adhesive orconventional fasteners.

[0024] In a preferred embodiment, the panel includes features whichallow it to overlap and to be structurally integrated into other panelsso as to form a continuous course. In such a fashion, a series ofcourses of panels may be aligned relative to each other to adopt thevisual appearance of natural stone or masonry.

[0025] The present invention also includes a method of fabrication ofthe aforedescribed panels. In one embodiment, the method of fabricationincludes the sequential steps of intermittently heating the panel,applying a base coating about the frontal surface of the panel,introducing a pigment on the frontal surface of the panel, applying oneor more texturing compounds to yield a desired texture and finish,applying one or more sealer coats to the textured coat and thenthermobinding all layers to each other and to the panel.

[0026] desired texture and finish, applying one or more sealer coats tothe textured coat and then thermobinding all layers to each other and tothe panel.

[0027] The present invention presents several advantages over prior artstructures and methods for their fabrication. A second benefit of theinvention is the design of the system which prevents moisture from beingtrapped between the substrate and the facing structure. In such afashion, degeneration of the facing and the system itself issignificantly reduced.

[0028] Another such advantage is the ease of fabrication. Panels of thepresent invention may be produced in an assembly-line process. In such afashion, the end product is of a consistent appearance and quality.Further, the ability to use an assembly-line process renders the systemmore economical than competitive systems.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029]FIGS. 1A-1B are perspective views of one embodiment of the panelsystem of the invention.

[0030]FIG. 2 is a detailed, perspective view of the embodiment of thepanel system of the invention illustrated in FIGS. 1A-1B.

[0031]FIG. 3 is a perspective view of one embodiment of the invention asshown in its intended application in a series of rows and courses.

[0032]FIG. 4 is a perspective, detailed view of one embodiment of theconnector tab system of the present invention.

[0033]FIG. 5 is a perspective, detailed view of a second embodiment of aconnector system of the present invention.

[0034]FIG. 6 is a side view of a drainage system operable in the presentinvention.

[0035]FIG. 7 is a perceptive view of a second embodiment of a drainagesystem operable with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] The system of the present invention comprises a series offabricated panels, each of which is adapted to be applied, incombination with other panels, to a surface so as to replicatealternating courses of cut stone or masonry.

[0037] In one embodiment, the panel 2 of the present invention defines afront 4 and a back 6 surface. When viewed in cross-section, the panel 2defines a profile having a top 8 and a bottom 10 flange. Each of flanges8, 10 define planar surfaces which are substantially coplanar to eachother. These flanges 8, 10 are adapted to attach to a mounting surface20, e.g. a wall, via conventional fasteners or adhesives (not shown).Flanges 8 and 10 bound a convex surface 18, as will be discussed below.Flanges 8 and 10 are designed to replicate a mortar joint when appearingin a series of horizontal courses, such as illustrated in FIG. 3.

[0038] Flanges 8, 10 bound a convex face surface 18 as shown in FIG. 2.This convex surface 18 extends outwardly from the mounting surface 20 inthe fashion of cut stone or masonry. In such fashion, the outward bow ofsurface 18 from surface 20 may be varied, depending on the type ofmasonry or stone sought to be imitated.

[0039] Panel 2 may be made from a variety of materials which can bemolded or thermoformed to a desired shape. It is contemplated thatacrylic/pvc, such as Kleerdex Vinyloy 103, may be used. Alternately, theuse of ABS and Styrene is also contemplated as being within the scope ofthe invention for use as panel 2.

[0040] The profile of panel 2 may be varied depending on the “look”sought to be replicated. In the instance of an acrylic/pvc, a flat panelmay be thermoformed into a desired shape in a manner familiar to thoseskilled in the art.

[0041] Panel 2 defines a first and second end, 22 and 24 respectively,as illustrated in FIG. 2. Both first 22 and second ends 24 are providedwith means to attach each panel to each adjacent panel comprising agiven course. In one embodiment, this attachment means may compromiseone or more studs or tabs 25 disposed at the first end 22 of each panel2 and a corresponding aperture(s) 28 disposed in the second end 24. Insuch a fashion, each panel 2 can be interconnected with adjacent panelsin a manner illustrated in FIGS. 1A-1B.

[0042] As illustrated in FIG. 4, the studs or tabs 25 may include anelongate stem 30 which defines an outside diameter larger than theinside diameter of aperture 28. Stem 30 may be bisected into multiplesubcomponents such that stem 30 may be compressed to fit into protrusion28 in a manner familiar to those skilled in the art.

[0043] Still other means of attachment are also envisioned within thespirit of the invention. By reference to FIG. 5, panels 2 may beprovided with a stud 40 about one end and a groove 42 about the oppositeend. Stud 40 may include along its length an area of a reduced radialdiameter which is receivable in groove 42, again in a manner familiar tothose skilled in the art.

[0044] These alternate means of interconnecting adjacent panels, inconjunction with the natural tendency of the convex faces of adjacentpanels 2 to “nest within each other” provides a ready means to ensureproper horizontal alignment of a course of panels 2.

[0045] It is inevitable that any surface exposed to the elements willallow some moisture to penetrate through to the mounting surface 20. Ifthis moisture was not allowed some method of escape or migration,retention of this moisture could result in deterioration of saidmounting surface 20. Alternatively, moisture collection in the airspace17 behind the panels 2, if not allowed means to dry, could also resultin a substantial deterioration of the panel 2. Further, moisturecollecting behind panel 2, when frozen, could weaken or destroy theadhesive bonds between panels 2 and the mounting surface 20.

[0046] In one preferred embodiment, each panel 2 is provided with one ormore moisture outlets 60. These outlets 60 are desirably formed on thelower portion of convex face 18, as illustrated in FIGS. 1A-1B and 2. Insuch a fashion, moisture, e.g. rain, will not be prone to enter theseoutlets 60 while conversely, moisture present behind panels 2 will bedisposed to exit void space 17.

[0047] Moisture outlets 60 may define a circular or semi-circular shape.In one illustrated embodiment, outlet 60 includes a partial cap or lid61 which extends over aperture 62. In such a fashion, greater resistanceto moisture intrusion may be obtained. Alternately, outlet 60 may beformed with intersecting grooves 63 such as illustrated in FIG. 7. Thisembodiment offers the benefit of preventing insects, e.g. wasps, fromentering said apertures and nesting in the void space 17.

[0048] The present invention is also directed to a method of fabricatingpanels 2. As set forth above, panel 2 is desirably formed from athermoformable material, e.g., cellular polyethylene, which is shapedvia the technique of thermo forming or plastic injection or rotationalmolding in a desired shape or series of shapes. Once formed, panel 2 isevenly heated about its front 4 and back 6 surfaces. This heating may beaccomplished via a hot air convection. It has been discovered that, inthe example of cellular polyethylene, an even heat of 80° F. is optimumto the fabrication process of the invention. This optimum temperaturerange, however, will vary depending on the material composition andthickness of the panel. This temperature is desirably maintained forsome fifteen minutes prior to the initiation of subsequent steps in theprocess.

[0049] Once heated to an optimum temperature, a base coating is appliedover the frontal surface 4 of the panel 2. This coating may include anacrylic polymer bonding agent. The purpose of this coating is to prepareand set up the molecular surface of the formed substrate with a bondingagent that allows color primer coat to make a mechanical and flexibleattachment to the said surface without direct interface with the face ofpanel 2. This coating may be applied by spray, brush or atomizationprocess in a manner familiar to those skilled in the art. The panel 2and the base coat is then heat-dried. In a preferred embodiment, thisdrying process may be accomplished by circulating hot air at atemperature of 168-170° F. for about fifteen minutes about the frontalsurface 4 of panel 2.

[0050] A primer coating is next applied over the base coat to thefrontal surface 4. This coating may include a DryVit Color Primer asmade by Dryvit Systems Inc., or other pigmented acrylic primer, e.g.Dryvit Color Prime This coating is then air dried, again at atemperature of between 100-120° F., for a duration of some fifteenminutes.

[0051] A first textured coating is then applied to the coated surface.This coating may comprise a mixture of one or more of an aggregate,sand, silica, quartz crystals, and a binder, e.g. DryVit, Stone Mist orDryVit Ameristone. The first textured coating is preferably applied to a50% coverage This mixture may again be sprayed, atomized or brushed overthe frontal surface 4 of panel 2. Once applied, this first texturedcoating is allowed to remain partially wet prior to the introduction ofthe next coating.

[0052] A solution of water-based or oil colored pigments and/or dyes isnext applied to the partially wet surface of the first textured coating.In a preferred embodiment, the mixture may be comprised of 100 partswater to 125 parts colored pigments and/or dyes. In the example of asand-colored texture, it has been discovered that a mixture of 100 partswater to 125 parts acrylic-based paint provides an optimum look andfeel. The pigment or dyes used in this step may include a number ofcommercially available products, e.g. DryVit® Color Primer or BenjaminMoore® Acrylic Paint. This pigment or dye solution is preferably appliedwith a “stacato” or rapidly flinging or irregular motion. Theapplication of this solution is also preferably applied under a selectedpressure and at a selected distance between the means of application andthe front 4 of panel 2.

[0053] The impact of the pigment or dye solution on the wet, firsttextured coating results in a wide dispersal of the pigment into a widevariety of shapes. The size and configuration of these shapes isdetermined by a number of factors including the pressure at which thepigment is applied, the viscosity of the pigment, and the distance ofthe surface 4 of panel 2 from the means of application. The applicationof the pigment onto the wet surface also results in a “bleeding” of thepigment solution into muted color tones, tints and contrasts. Each ofthe variables may be altered again depending on the pressure ofapplication, the viscosity of the mixture and the distance of the meansof application to the front surface 4 of panel 2.

[0054] A second textured coating is next applied to the substrate. Thissecond textured coating may again be comprised of a mixture of one ormore of aggregate, sand, silica, quartz crystals and a 100% acrylicbinder. This coating is preferably partial (as opposed to complete) inorder to highlight textures felt desirable for the particularapplication. In this connection, it may be desirable to use a differentmixture of texturing agents, or to apply the texture in a differentmanner, than the initial texture coating to achieve optimum results.

[0055] If desired, an additional coating of a colored solution may beadded, as desired. Additionally, additional or varying textured layersmay also be applied to reach a desired color and texture.

[0056] Once a desired texture and color is achieved, a sealer is appliedto the front surface 4 of the panel 2. This coating preferably comprisesa semi-gloss or high gloss, e.g., DryVit® Demandit 100% clear acryliccoating, again dependent on the desired end application. Over thiscoating, a second flat, semi-gloss or high gloss coat is applied, withthis procedure being repeated to replicate the depth or field of depthof strata found in natural stone, marble, graphite or limestone.

[0057] The coated and textured substrate is then preferably heated to atemperature of between 168-170° F. for some fifteen minutes to completethe drying process. Each panel 2 of the system is then ready forinstallation.

[0058] An example of one embodiment of the fabrication method of thepresent invention is set out below.

EXAMPLE 1

[0059] A sheet of acrylic/pvc (Kleerdex Vinyloy 103, Acrylic/PVC, P-1haircell texture) having a thickness of 0.040 and/or 0.60 wasthermoformed into a stone or a stone molding configuration. The sheetwas evenly heated to 80° F. A base coating (Quickstone Conditioner) wassprayed over the face of the pre-heated acrylic/pvc formed sheet. Thesubstrate and base coating was heat dried by circulating hot air at atemperature of 100° F., for the duration of approximately fifteenminutes. A primer coating (DryVit® Color Primer) was then sprayed overthe surface of the base coating. The sheet, base coating and color primewere then heat dried by circulating hot air at a temperature of 100° F.,for a duration of fifteen minutes. An initial or first and partialcoating of a mixture of aggregate, silica, sand, quartz crystal and 100%DryVit acrylic binder emulsion was then sprayed over the face of thepre-formed and base coated sheet. The partial coating on the surface ofthe sheet was allowed to remain wet. A solution (100 parts water to 125parts acrylic-based paint) of DryVit® Color Primer was applied onto thewet surface. The solution was mechanically applied with a “staccato”motion to produce color muting, bleeding, graduation and blotching. Asecond partial coating of a mixture of aggregate, sand, silica, quartzcrystal and 100% acrylic binder emulsion (DryVit® Stone Mist) wassprayed onto the face of the pre-formed sheet. The sheet and base coat,prime coat and aggregate coatings was then heat dried by circulating hotair at a temperature of 100° F., for a duration of approximately fifteenminutes. A flat, semi-gloss or high gloss (DryVit® Demandit 100% clearacrylic coating) was then applied over the second partial coating to actas a sealer. A solution of a flat sealer coat (DryVit® Demandit 100%clear acrylic coating) was then applied over the second partial coatingto replicate the depth of field. The formed sheet with the completedbase coat, prime coat and aggregate coats and clear acrylic coatings(DryVit® Demandit 100% Clear Acrylic coating) was then heat dried bycirculating hot air at a temperature of 170° F., for a duration ofapproximately fifteen minutes.

[0060] An alternative method of fabrication also utilizes athermoformable panel, as described above. A solution of water-basedpigments, dyes, emulsions or acrylics, or combinations of thesecompounds, are sprayed or atomized over the surface of a body oftemperature-regulated water such as may be maintained in a vat or pool.By their nature, these compounds are lighter than water and thus form asheen- or film on the water surface. This film forms intoirregularly-shaped puddles as the pigment mixture and the water mutuallyrepels each other.

[0061] A panel again preferably comprising a thermoplastic panel, isheated to a temperature of some 80° F. To this heated surface, a basecoat, e.g. an acrylic polymer bonding agent is applied via spraying,brushing or atomization over the face of the preheated panel. Thesubstrate and base coating are heat dried by circulating hot air at atemperature of 100° F. for some fifteen minutes.

[0062] A primer coating is then applied to the base coating by brush,spray or atomization. This coating is also heat dried by circulating hotair at a temperature of between 100° F. for some fifteen minutes.

[0063] A coating of aggregate, silica, sand, quartz, and 100% acrylicbinder emulsions (Dryvit Stone Mist #25 sized stone) was sprayed ontothe face of the primer coat, base coat and pre-formed substrate. Thesubstrate, base coat, primer coat and aggregate coat was then heat driedby circulating air at a temperature of 100° F., for the duration of 15minutes.

[0064] The coated, front surface of the heated panel is lowered into thefilm emulsion. This film adheres to the panel in the irregular patternwhich is maintained in the vat or container. This film serves to enhancethe natural, fragmented, colored, distressed, aged, antiqued colorand/or toned qualities of natural stone. The end product is again heatedto 170° F. to promote curing.

[0065] An example of this second method of fabrication is set forthbelow.

EXAMPLE 2

[0066] A sheet of acrylic/pvc (Kleerdex Vinyloy 103) having a thicknessof 0.040 was thermoformed into a stone molding configuration. The sheetwas then evenly heated to 80° F. A base coating (Quickstone Conditioner)was then sprayed over the face of the pre-formed, pre-heated acrylic/pvcformed sheet. The substrate and base coating was then heat dried bycirculating hot air at a temperature of 100° F., for the duration ofapproximately fifteen minutes. A primer coating (DryVit® Color Primer,pigmented acrylic polymer) was then sprayed over the surface of the basecoat and preformed substrate. The substrate, base coating and prime coatwere then heat dried by circulating hot air at a temperature of 100° F.,for a duration of approximately fifteen minutes. A coating of aggregate,sand, silica, quartz crystals and 100% acrylic binder emulsions (DryVitColor Primer) was then sprayed over the face of the primer coat, basecoat and pre-formed sheet. The substrate, base coat, primer coat andaggregate coat were then heat dried by circulating hot air at atemperature of 100° F., for a duration of approximately fifteen minutes.

[0067] A reservoir filled with water was heated to a temperature of 100°F. An antiquing solution of a water-based pigments (Quickstone® CustomAntiquing Colored Acrylic Paint) in a solution of 100 parts water to 125parts acrylic, enamel paint was sprayed over the surface of thetemperature regulated water to produce an irregular film.

[0068] The sheet, base coat, primer coat and aggregate coat was immersedface down into the floating film. The film maintained its irregular andshaped puddle effect as it adhered itself to the surface of the coatingand thus created the desired replication and effects of naturallyfragmented, colored, distressed, aged, antique, color and tonalqualities of natural stone. The substrate, base coat, primer coat,aggregate coat and antique coat were then heat dried by circulating hotair over the front surface of the sheet at a temperature of 120° F. forthe duration of approximately fifteen minutes.

[0069] Although particular detailed embodiments of the apparatus andmethod have been described herein, it should be understood that theinvention is not restricted to the details of the preferred embodiment.Many changes in design, composition, configuration and dimensions arepossible without departing from the spirit and scope of the instantinvention.

What is claimed is:
 1. A wall panel adapted to be fastened to a mountingsurface, said panel comprising: (a) a formed, thermoplastic paneldefining a back and a front surface where said front surface isoutwardly-curved whereby said outwardly-curved surface is bounded by oneor more attachment flanges where each said flange extends to saidmounting surface, said curved surface defining a void space between saidmounting surface and said outwardly curved surface; and (b) said frontsurface of said panel including: (i) one or more textured layers; and(ii) one or more pigmented layers, where each of said layers arethermobonded to said panel.
 2. The wall panel of claim 1 furtherincluding means to attach a given panel to adjacent,horizontally-oriented panels.
 3. The wall panel of claim 2 where saidpanel further defines a first and second end where each said first endincludes a male connector which is receivable in a female connectordisposed on said second end on an adjacent panel.
 4. The wall panel ofclaim 1, wherein each said mounting flange defines a planar surfacewhich is adapted to contact said mounting surface.
 5. The wall panel ofclaim 1 wherein the thermoplastic panel is made of acrylic.
 6. The wallpanel of claim 1 further including means to drain any fluid trapped insaid void space.
 7. The wall panel of claim 6 wherein said drainagemeans includes one or more apertures formed on a bottom-most portion ofsaid curved surface.
 8. The wall panel of claim 1 wherein said texturedlayers are partially comprised of a mixture including an aggregate,sand, silica, quartz crystals and a binding agent.
 9. The wall panel ofclaim 7 where said aperture includes means to limit access into the voidspace through said aperture.
 10. The wall panel of claim 1 where saidattachment flange, when said panel is joined to the other panels in aseries of horizontal courses, resembles a motor joint.
 11. A sidingassembly for an exterior wall surface made up of a plurality of sidingunits, said units adapted to be affixed to the wall surface with similarunits in overlapping horizontal courses with the units of each courselying in overlapping relation to each other, each of said unitscomprising: a main body portion including a front face and a rear face,said front face including a substantially convex main portion bounded byone or more linear lip portions; and said front face defining at one enda male connector where said male connector is adapted to fit into anaperture in an adjoining siding unit, said front face defining at theopposite end a female connector adapted to receive a male connectordisposed on an adjoining siding unit; said lip portion adapted tocontact said wall surface such that the convex portion defines a voidspace between said rear face and said wall surface; and a textured layerthermobonded to said front face.
 12. The siding assembly of claim 11wherein said front surface defines means to drain the void space. 13.The siding assembly of claim 12 wherein said drainage means comprisesone or more apertures disposed in the lower surface of the convex mainportion such that any moisture collecting in said void space may passthrough said aperture.
 14. The siding assembly of claim 11 where saidmain body portion is comprised of a thermoformable material.
 15. Thesiding assembly of claim 14 where said thermoformable material includesacrylic/pvc.
 16. The siding assembly of claim 11 wherein said texturedlayer includes alternating layers of a texturing agent and a pigment.17. The siding assembly of claim 11 where said textured layer is formedfrom a method comprising the steps of: (a) heating the main bodyportion; (b) applying a base coating to the front surface of said mainbody portion; (c) drying said base coat about said main-body portion;(d) applying a primer coat to the front surface of said main bodyportion; (e) heat drying said primer coat for a selected time interval;(f) applying a textured coating; and (g) heating the main body portionto dry each for a selected time interval.
 18. The method of claim 17further including the steps of: (a) applying a pigment to the texturedcoating; (b) heat drying the coating for a selected time interval; and(c) applying a sealer to the frontal surface of the main body portion.19. The method of claim 17 wherein the textured coating is drawn from agroup consisting of one or more of an aggregate, sand, silica, and/orquartz crystals and a binder emulsion.
 20. The method of claim 17wherein the main body portion is heated to a temperature of 80° F. 21.The method of claim 17 where the steps of heat drying occur in a rangeof 120-170° F.
 22. The method of claim 17 where the pigmentation isapplied irregularly over the textured surface.
 23. A facing panelstructure for a wall comprising a plurality of sheets whose outersurface is contoured for simulating at least one of various constructionfacing materials, positioned thereon in spaced relation with each otherand with mortar line portions simulated between said constructionmaterial, each of said sheets having flange portions extending one ormore edge portions, said flange portions bounding a substantially convexportion, said convex portion defining at one end a mating protrusion andat the second end a mating aperture adapted to receive the matingportion from an adjacent panel structure, said convex portions definingone or more drainage apertures about their bottom surface, whereby uponmounting said sheets of material on said wall said mating protrusions ofone sheet are received in said mating protrusion on adjoining sheets ofmaterial, said outer surface of said panel provided with a pigmented,textured coating which is sealed and thermally bonded to said outersurface.
 24. The facing panel structure of claim 23 wherein saidsubstantially convex portion of said sheet defines a void area betweenthe facing panel structure and the wall.
 25. The facing panel of claim23 wherein said sheets are formed of a cellular polyethylene.
 26. Thefacing panel of claim 23 wherein the textured coating is applied usingthe sequential steps of: (a) applying a base coating to the frontsurface of said sheet; (b) drying said base coat about said sheet; (c)applying a primer coat to the front surface of said sheet; (d) heatdrying said primer coat for a selected time interval; (e) applying atextured coating; (f) applying a pigment to the textured coating; (g)heat drying the coating for a selected time interval; (h) applying asealer to the frontal surface of the sheet; and (i) heating the sheet todry each for a selected time interval.
 27. The method of claim 25further including the initial step of first heating the sheet.
 28. Asiding assembly for an exterior wall surface made up of at least a firstsiding unit and a second siding unit where each of said siding unitsdefines a front and back surface, each of siding units comprising: abody molded in a described configuration to define a face surfacebounded by one or more attachment portions, the front surface of saidbody including one or more textured layers bonded to said surface; saidbody including a first and a second end where said first end includes araised portion and said second end defines an aperture, where saidraised portion is adapted to be received in said aperture formed in saidsecond siding unit to align said horizontal flange portions of the firstand second siding unit; said flange portion defining a substantiallycoplanar surface adapted to contact said wall surface; said firstsurface defining a void area between said back surface and said wall;and means to allow the drainage of moisture which may collect in saidvoid area.
 29. The siding assembly of claim 28 wherein the body iscomprised of a thermoplastic.
 30. The siding assembly of claim 28wherein the body is comprised of a moldable material.
 31. The sidingassembly of claim 28 wherein said flanges are formed horizontally.
 32. Amethod of manufacturing a siding member which includes a base memberhaving a front and back surface, comprising the steps of: (a) applying afirst base coating to a front surface of the base member; (b) applying asecond, primer coating to said first surface of the base member; (c)applying a third textured coating to said first surface of said basemember; (d) applying a fourth, pigmented coating to said first surfaceof said base member; (e) applying a fifth sealant coat to said fourth,pigmented coating; and (f) curing said multiple layers.
 33. The methodof claim 31 further including the step of applying a fifth sealant coatto said fourth, pigmented coating.
 34. The method of claim 31 furtherincluding the steps of curing the first and second layers prior to theapplication of a subsequent layer.
 35. The method of claim 31 where saidcuring step is accomplished by circulating a hot gas across the frontsurface of said bound member.
 36. The method of claim 31 wherein saidgas is air.
 37. The method of claim 31 where the gas is heated to atemperature in the range of 100-120° F.
 38. The method of claim 31further including the step of first forming the base member into aprofile having a convex face bounded by horizontal flange members. 39.The method of claim 31 where the textured coating comprises a bindingagent and one or more compositions drawn from the group of aggregate,sand, silica or quartz crystals.
 40. The method of claim 31 wherein thecoatings are sprayed, atomized, brushed or trowelled.
 41. The method ofclaim 31 where in the hot gas is applied to the front surface forapproximately fifteen minutes.
 42. The method of claim 31 furtherincluding a step taken prior to the application of the sealing coatingwherein the textured frontal surface is immersed in a mixture of waterover which has been dispersed a coating of a water-insoluble pigment.43. The method of claim 41 where the water/pigment mixture is in therange of 100 parts water and 125 parts pigment.